ML20039C608

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QA Program Insp Rept 99900378/81-01 on 811012-16. Noncompliance Noted:Failure to Post Current Copy of 10CFR21 & Procedures for Implementation of 10CFR21 Not Adopted
ML20039C608
Person / Time
Issue date: 12/08/1981
From: Barnes I, Foster W
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20039C596 List:
References
REF-QA-99900378 NUDOCS 8112290517
Download: ML20039C608 (14)
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{{#Wiki_filter:NAMCO CONTROLS DIVIS20N ACME CLEVELAND CORPORAT10N ORGANIZATION: JEFFERSON, OHIO REPORT NO.: 99900378/81-01 INSPECTION DAMS): 10/12-16/81 INSPECTION ON4ITE HOURS: 56 CORRESPONDENCE ADDRESS: NAMC0 Controls Division Acme - Cleveland Corporation ATTN: Mr. N. E. Swanson President 149 Cucumber St. Jefferson, Ohio 44047 ORGANIZATION CONTACT: Mr. J. Bentley, Manager-Quality Assurance TELEPHONE: (216) 576-4070 PRINCIPAL PRODUCT: Limit Switches. NUCLEAR INDUSTRY ACTIVITY: It is expected that 805 shippers (purchase orders / con-tracts) for switches will be processed between October 1,1981, and September 30, 1982. ASSIGNED INSPE R: 8c % /2 - 2. - F / 9 T. nster, Reactive Inspection Section (RIS) Date OTHER INSPECTOR (S): L. B. Parker RIS APPROVED BY: i z - 2. - P # I. Barnes, Chief, RIS Date INSPECTION BASES AND SCOPE: A. BASES: 10 CFR Part 50, Appendix B; 10 CFR Part 21; and other NRC requirements. B. SCOPE: This inspection was conducted as a result of: (1) identification of intermittent operation of limit switches; and (2) concerns expressed by Region III of the U.S. Nuclear Regulatory Comission, regarding adequacy of the NAMCO quality assurance program. Inspection areas selected to evaluate the foregoing were: QA reinspection; manufacturing process control; and change control. Control of measuring and test equipment and follow up on 'nbnconfortnances were also evaluated. csion".:D 03IcII:1.L f (gr,39g3 gg-{,f,Q)M & E o PDR

NAMCO CONTROLS DIVISION ORGANIZATION: ACME CLEVELAND CORPORATION JEFFERSON, OHIO REPORT NOJ 99900378/81-01 INSPECTION RESULTS: PAGE 2 of 4 A. VIOLATIONS: 1. Contrary to paragraph 21.6 of 10 CFR Part 21, a current copy of 10 CFR Part 21 was not posted 2. Contrary to paragraph 21.21 of 10 CFR Part 21, procedures had not been adopted to implement 10 CFR Part 21. B. NONCONFORMANCES: 1. Contrary to Criterion V of Appendix B to 10 CFR Part 50, paragraph 2.2.1, its subparagraph 2 and paragraph 2.3 of Section 5.0, Revision B, of the QA Manual, Revision C, dated May,1981, Production Order Travelers had not been controlled to ensure that delivered items are fabricated, processed, and accepted to the latest design configuration in effect; as evidenced by the following conditions noted on the Production Router for Part No. EA742-32701, Production Order No. C21187: (a) an unauthorized deletion on October 12, 1981, of an engineering requirement (Oper. No. 0180-Impregnate and Water Test); and (b) nonaccomplishment of a reaming operation (no. 0090), which had been discontinued for at least two years. Note: The last inspection operation of the Production Router had been stamped and dated. 2. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph 5.5 of NAMC0 Standard Practice (NSP) No. 60-0007, re-issue date August 1981, nuclear product inspection had not been controiled per Q.C. No. 10-101, as evidenced by lack of documentation required by Q.C. No. 10-101. 3. Contrary to Criterion V of Appendix B to 10 CFR Part 50, and paragraph 6.1 and its subparagraph 1 of Section 20.0, Revision A, of the QA Manual, Revision C, dated May,1981, final inspection had not been perfomed to provide conformance to the approved drawing on Lever Shaft, Part No. EA186-00099 for Factory Order No. C26097. Inasmuch as the parts were accepted to an unauthorized changed dimension of.496/.498 inches the inspection record indicated that the parts were within the drawing dimension of.499/.497 inches. 4. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph 6.5.1.2 of NSP No. 40-0003, re-issue date August 1981, nuclear factory orders had not been reviewed by Engineering for engineering documentation currentness just prior to issuing orders to the shop floor. Examples: Factory Order Nos. C26558, C26097 and C25575. 5. Contrary to Criterion V of'Asipendix B to 10 CFR Part 50 and paragraph 2.2 of Section 14.0, Revision A, of the QA Manual, Revision C, dated May 1981, the use of calibrated equipment had not been' identified in completed travel-

  • ers for the following hardware items which were processed June 26 through August 6, 1981, and required use of calibrated equipment during assembly and test:.(a) Assembly Number (AN) EA180-31302, Factory Order Number (FON)

C-26097; (b) AN EA180-32302, FON C-26558; and (c) AN-EA740-20000, i

NAMC0 CONTROLS DTVfSION ACME CLEVELAND CORPORATION ORGA " " JEFFERSON, OHIO REPORT NO.: 99900378/81-01 INSPECTION RESULTS: PAGE 3 of 4 FONs C25575, and C24879. The calibrated equipment consisted of torq'e u screwdrivers, gauges and electrical test fixtures. 6. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph 5.2.4 of QA Manual Section 15.0, Inspection Report 3406393 was not signed off by the manufacturing, production control, and engineering representatives of the material review board. 7. Contrary to Criterion V of Appendix B to 10 CFR Part 50, and paragraph 2.4 of QA Manual Section 6.0, changes to NAMCO Standard Procedures (NSP) are not controlled. Example: NSP 20-0001 sign off sheet shows final approval on October 17, 1980, however, NSP 20-0001 sheet 2 indicates an unapproved reissue date of August,1981. 8. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraphs 3.1.l' and 3.1.2 of QA Manual Section 18, Revision B, the yearly audit schedule and quality element checklists had not been prepared. C. UNRESOLVED ITEMS: 1. NSP-60-0006 paragraph 5.1.3 states that internal audits will be performed at least annually, while NQAM Section 18 paragraph 2.2 sets the interval at 36 months. 2. NAMC0 Controls Engineering Department Procedures dated April 18, 1980, paragraph 4.2.2 does not impose the use of the same engineering change control order as does NQAM Section 3.0 paragraph 4.2. D. STATUS OF PREVIOUS INSPECTION FINDINGS: (0 pen) Deviation (80-01): Failure to provide documented procedures in the areas ef: auditing, purchasing, material storage, engineering and calibra-tion. Procedures have been written but not implemented as written for in-ternal audits (see nonconfonnance 8). Procedures have been written and implemented for engivering changes and design review, a material review board, calibration, procurement control, and material storage. E. OTHER FINDINGS OR CGMMENTS: 1. Manufacturing Process Control - NAMC0 Standard Practice No. QC 10-101, dated October 1, 1979, establishes sampling plans and procedures for inspection of " items used in Nuclear Applications." It also states the inspection results must be recorded on specific forn.s identified in the document. The inspector was informed that the program had not been implemented. a. The Inspection Record for the Lever Shaft, reflected an ink change -on the diameter from.499/.497 inches to.498/.496 inches. There was no engineering documentation to authorize the change. In the final analysis, the Inspection Record indicated the parts were within 5

NAMCO CONTROLS DIVISION ORGAN!ZADON: ACME CLEVELAND CORPORATION JEFFERSON, OHIO N N O.: 99900378/81-01 INSPECDON RESULTS: PAGE 4 of 4 the drawing dimensions of.499/.497 inches. c. The Production Planner requisitions engineering documents from the Secretary / Clerk - Engineering just prior to issuing the orders to .the shop floor as opposed to review by Engineering. d. The 11 switches that exhibited intermittent operation at the Quad-Cities Nuclear Power Station were received at NAMC0 controls on Returned Goods Report (RGR) No. 5891, dated May 7,1981. Remarks in the RGR indicated confirmation of intermittent operation, however, the test voltage was not shown. Records indicate that the returned switches were upgraded to Revision H (from Revision G) and shipped to Commonwwalth Edison on May 28, 1981. The Assembly Procedure required an electrical test at 6 volts direct current,100 milliampers. 2. QA Reinspection - The Quality Assurance Manual Revision Record indicates that the Manual, dated May 1981, is a complete revision, and correlates with Appendix B of 10 CFR Part 50. All of the NAMC0 Standard Practices (18) are dated from October 1980 through July 1981; with nine of them exhibiting a reissue date of August 1981. 3. Control of Measuring and Test Equipment - Procedures (2) and records (9) were inspected in this area. The procedures were implemented. The records inspected were current and, where applicable, traceable to the National Bureau of Standards. 4. Change Control ~- Procedures (16) and records (24) were inspected in this area. Design fabrication and inspection change control procedures were delineated and implemented, except for deficiencies noted. e 8 e O

PERSONS CONTACTED NA M C C C owTn cL s Div. Company ACN C-C L E v CL A MD L O R t. Dates & e he l,e n i 2. ) G, ! 9 f l Docket / Report No. 9 9 9 00 3 7 8 [81-CI Inspectort U.c. Fes/en[L n. P4n lcer Page i of / NAME(Please Print) TITLEfPlease Print) ORGANIZATION (Please Print) a J. R. Sen de k4: l;r Fre e c e l F, o : n c e n Eno neen:si u u , 3. 4. Bedley /%n 4,ee n - 0.I:4,. 431-..w<e o m e l:/, Ai,- n,, < e d. b: C;., on, n,4y,n_ n., f.el,_o:sf /% n m /,, /m m : o E. 3%ncent. Prt.J u d:e n Pl4%nen Fie. J, /, % C onin e l D. k allay P-ed.,:nd A.ent Puuk a r ;n i o R. E l oo n l: nassiew-Oust:lu Cen$nel Q-al;l., Con lnel y, n a. CI:n l;e Scene on y /t te nte c, g ; n e e rt :, e-T ).1% nork: Leal rnrocalen O p(;l., Con /nef L. E. tJ 4 n j V:c t Ibi:Je x / - /b /41 - AJ m:n:r /n 4/te n tw e ( Ew o: ween:, d 6 6 a ' M,le / Ex:/ r,bs:e a. 4 e-e

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